EVA Safety Helmet

ABSTRACT

A pliant EVA helmet that conforms to a patient&#39;s head. The helmet is fabricated as a single unit via a molding process. The EVA material provides a stable lightweight structure that allows it to be comfortably worn for extended periods of time. The EVA shell is molded into a protective shell that can optionally be covered by a suitable pliant external layer of material. Optional pockets can be positioned on the inside or outside of the helmet such that thermal packs can be installed in the pockets to provide thermal treatment to the wear.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to, and claims the benefit of, the commonly owned provisional patent application, now expired, entitled “Thermal Safety Helmet For Treating Head Injuries”, filed Oct. 16, 2012, bearing U.S. Ser. No. 61/714,732 and naming Daniel M. Shapiro, the named inventor herein, as sole inventor, and the commonly owned co-pending non-provisional application emitted “Thermal Safety Helmet For Treating Head Injuries”, filed Oct. 16, 2013, bearing U.S. Ser. No. 14/055,848 and naming Daniel M. Shapiro, the named inventor herein, as sole inventor, the contents of both applications are specifically incorporated by reference herein in their entirety.

BACKGROUND

1. Technical Field

This invention relates in general to safety devices, and more particularly it relates to an ethylene-vinyl acetate (“EVA”) helmet that is worn to protect an individual's head while a head injury is healing, protecting an individual's head from additional injury, and/or protecting an individual's head from sustaining an initial injury.

2. Background of the Invention

Padded helmets are commercially available to protect a wearer's head in a variety of situations. They are used by athletics in a variety of sports. These devices, such as football helmets, typically provide impact protection, but typically are heavy and uncomfortable to wear. Further, they become more comfortable with time due to the effect of weight. Likewise, padded helmets are available for treatment of a variety of medical conditions, most notably to protect patients with head injuries from inadvertently sustaining subsequent injuries. Medically oriented helmets also have the same drawbacks in regard to weight and comfort. It would be desirable to have a low weight helmet that can provide a high level of protection while being comfortable to wear.

Thermal considerations related to this and that many uses of helmets extend from the casual headwear, such as sporting equipment, to medical devices. The comfort and wake considerations, discussed above, are also factor in special-purpose headwear, such as thermal helmets. Casual headwear, such as baseball caps, are known to have been used In conjunction with cooling devices for the purpose of keeping an individual cool and participating in outdoor activities. These devices typically use pre-cooled pouches containing ice, cold water, or gel that are positioned at the back of the wearer's head or around the neck. This type of headwear typically does not provide the wearer any protection, except from sunlight.

Some casual headwear even go so far as to provide water filled pouches that allow water to slowly be released on to a wearer's head such that heat from the wearer's body evaporates the water to create a cooling effect. Of these devices, some use a headband and the cap, and others use larger compartments that emit water over the entire wearer's head. These devices can provide relief from heat, but can also be uncomfortable due to the constant release of moisture onto a wearer's head.

Impact resistant headwear, such as sports helmets (e.g., football helmets), and protected medical headwear both provide impact protection. However, neither combine impact protection with thermal control elements that allow an individual's came to be either cooled or warmed at the individual's discretion.

Another disadvantage of the prior art is that prior art help us are typically fabricated from a number of components that increase the cost of materials, and increases the chance that defective products will be manufactured due to complexity. It would be desirable to have the helmet that can be manufactured as a single component and a low-cost.

While the prior art has provided basic impact protection, it has failed to provide a helmet shell that is fabricated as a single unit. Nor has it provided the ability to incorporate therapeutic properties, such as the application of thermal treatments to selected areas of an individual's head.

SUMMARY OF THE INVENTION

This invention provides a pliable padded EVA helmet that conforms to a patient's head. The helmet is fabricated as a single unit via a molding process. The EVA material provides a stable lightweight structure that allows it to be comfortably worn for extended periods of time. The EVA shell is molded into a protective shell that can optionally be covered by a suitable pliant external layer of material. Optional pockets can be positioned on the inside or outside of the helmet such that thermal packs can be installed in the pockets to provide thermal treatment to the wear.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a preferred embodiment of the thermal safety helmet with ventilation apertures on the surface of the helmet.

FIG. 2 is a top view of a preferred embodiment of the thermal safety helmet showing ventilation apertures on the upper surface of the helmet.

FIG. 3 is a left side view of a preferred embodiment of the thermal safety helmet showing an ear aperture, a strap attachment aperture, and ventilation apertures on the surface of the helmet.

FIG. 4 is a right side view of the preferred embodiment of the thermal safety helmet showing an ear aperture, a strap with optional chin pad, and ventilation apertures on the surface of the helmet.

FIG. 5 is a rear view of a preferred embodiment of the thermal safety helmet showing a strap attached to it, and ventilation apertures on the surface of the helmet.

FIG. 6 is an inside plan view of a preferred embodiment of the helmet showing an internal thermal pockets. This figure also illustrates how the inside surface of the thermal safety helmet can be fabricated from a single piece of material.

FIG. 7 is a front view of a preferred embodiment of an EVA safety helmet with an optional chinstrap on the surface of the helmet.

FIG. 8 is a top view of a preferred embodiment of the EVA safety helmet showing ventilation apertures on the upper surface of the helmet.

FIG. 9 is a left side view of a preferred embodiment of the EVA safety helmet showing an ear aperture, and a strap attachment aperture on the surface of the helmet.

FIG. 10 is a rear view of a preferred embodiment of the EVA safety helmet showing a strap attached to it, and ventilation apertures on the rear surface of the helmet.

FIG. 11 is a cross-sectional view of a preferred embodiment of the EVA helmet showing an internal EVA layer with optional external cover layers on either side.

FIG. 12 is a side view of a preferred embodiment of the EVA helmet showing an optional ornamental image on the side of the helmet.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Prior to a discussion of the figures, an overview of the invention will be presented. The invention is an apparatus and method for applying thermal treatments to head injuries or conditions while simultaneously providing impact protection for patients. The invention protects and treats injuries that have already occurred, and also protects the head from subsequent injuries. In some cases, as when children or adults have chronic or pre-existing conditions, the helmet may be worn prior to any actual injuries. The invention uses a pliable padded helmet that conforms to a patient's head such that the patient is protected from impacts. This is especially important for children who may not be as careful about protecting head injuries. The helmet is fabricated with pockets that hold thermal packs that can be hot or cold depending on the treatment intended for an injury, an infection, etc. The pockets can be positioned on the inside or outside of the helmet. The preferred embodiment envisions replaceable internal thermal packs, but optionally, the thermal packs can be an integral part of the helmet and non-removable. The thermal packs can provide heat or cold depending on the condition being treated. The helmet also includes ventilation apertures to provide airflow for the patient's comfort.

The helmet can be fabricated from a variety of materials. The only requirement is that the materials chosen be suitable for the helmet's intended purpose. While a wide variety of materials can be used to fabricate the thermal safety helmet, a preferred combination of suitable materials used in the preferred embodiment of the invention is the use of an external surface of Lycra™ Sport Fabric in combination with an internal surface of Poron™ Plus foam cushioning. These materials provide several advantages. Poron can be stamped as a single piece during manufacture, as illustrated in FIG. 6. Further, it offers high rebound properties that are important in protecting patients from additional injuries when treating a previous injury or condition. It provides an open cell, reasonable structure that allows ventilation. In addition, it has antifungal properties that are important when treating head injuries that may be susceptible to infection. The use of the Lycra Sport Fabric as an outer surface provides protection from unnecessary wear to the internal Poron layer, and provides additional strength and longevity to the thermal safety helmet.

In the preferred embodiment, the inside Poron layer will have two layers. The outer layer is envisioned as having a 9.5 mm layer, and a 6 mm inner layer. Two layers are used to provide the ability to form pockets between the inner and outer layers such that thermal packs can be inserted into the pockets. The Poron layers can be stamped from single sheets of material, and bonded together with an adhesive.

Likewise, in the preferred embodiment the outer layer of Lycra Sport Fabric was selected because it is a lightweight, breathable, and comfortable material. Lycra is resistant to sunlight, ultraviolet light, chlorine, and static cling. It provides an effective layer of protection for the inner Poron foam and protects it from the environment. The Lycra can be adhered to the Poron via adhesive. Those skilled in the art will recognize that the invention can be implemented with a single outer layer of Lycra. However, in the preferred embodiment, two Lycra layers are used to encapsulate the Poron foam. The use of an additional inner Lycra layer provides improved longevity and comfort.

In regard to the chinstrap, a preferred embodiment envisions the use of a nylon strap that was chosen due to its strength and durability properties. Likewise, the straps are commercially available and can be manufactured with integral hook and loop attachment surfaces. In addition, an optional cushioned sleeve can be provided such that, when the strap is secured to the patient, the chinstrap will be covered by the cushioned sleeve for the patient's comfort.

The shape of the helmet can also vary depending on the size of the patient as well as the type of affliction the helmet is intended to treat. Further, the optional chinstrap, as illustrated in FIG. 4, can be used to secure the helmet to the patient.

An improved version of the helmet uses an EVA shell fabricated as a single unit, preferably using a molding process.

EVA has been discovered to exhibit highly desirable properties for use in helmets. Ethylene vinyl acetate is the copolymer of ethylene and vinyl acetate. The ethylene typically comprises sixty to ninety percent of the EVA weight, while the vinyl acetate component usually comprises from ten to forty percent of the weight. EVA has desirable characteristics in that it is similar to elastomeric materials in softness and flexibility, but has an advantage in that it can be processed like numerous types of thermoplastics. EVA has a combination of qualities such as good clarity and gloss, low temperature toughness, adhesive properties, crack resistance, waterproof properties, and resistance to UV radiation.

EVA is a component in a variety of products, including hot melt adhesives, hot glue sticks, plastic wraps, children's foam stickers, and medical applications (i.e., drug delivery devices). EVA is an expanded rubber (i.e., foam rubber). EVA is buoyant, and is useful in products that are intended to float. It can be used as an encapsulation material for silicon cells in the manufacture of photovoltaic modules. EVA, is also used in the formulation of paints.

Having discussed the invention in general, we turn now to a detailed discussion of the drawings.

FIG. 1 is a front view of a preferred embodiment of the thermal safety helmet 1 with ventilation apertures 2 on the surface of the thermal safety helmet 1. Also shown is a portion of the optional chinstrap 3 extending from the thermal safety helmet 1. In operation, the chinstrap 3 is inserted through chinstrap aperture 5 (shown in FIG. 3) and then preferably secured by integral hook and loop material 8 (shown in FIG. 5) on chinstrap 3. Any suitable method of securing the chinstrap 3 may be used, but hook and loop material 8 is preferred since it is inexpensive and easy to use. Optional side panels 4 are also shown, but those skilled in the art will recognize that the actual shape of the helmet 1 will vary based on the intended use and the patient's needs. As a result the side panels 4 may not be necessary in a given situation. Likewise, the number and shape of the external (or internal) pockets 3 (shown in FIG. 6) can vary. Of course, the chinstrap 3 can be attached to either side of the thermal safety helmet 1.

FIG. 2 is a top view of a preferred embodiment of the thermal safety helmet 1 showing ventilation apertures 2 on the upper surface of the thermal safety helmet 1.

FIG. 3 is a left side view of a preferred embodiment of the thermal safety helmet 1 showing an ear aperture 6, a strap attachment aperture 5, and ventilation apertures 2 on the surface of the helmet.

FIG. 4 is a right side view of the preferred embodiment of the thermal safety helmet 1 showing an ear aperture 6, a chinstrap 3 with optional chin pad sleeve 7, and ventilation apertures 2 on the surface of the thermal safety helmet 1. Optional chinstrap sleeve 7 provides a soft and comfortable cushion for the patient's chin. Once the chinstrap 3 is inserted into strap aperture 5 and secured via hook and loop material 8, the chinstrap sleeve 7 is slidably moved over the chinstrap 3 such that the hook and loop material 8 is covered up.

FIG. 5 is a rear view of a preferred embodiment of the thermal safety helmet 1 showing a chinstrap 3 attached to it, and ventilation apertures 2 on the surface of the thermal safety helmet 1. Also shown in this figure is the hook and loop material 8 on chinstrap 3.

FIG. 6 is an inside plan view that illustrates how both the Poron layers and the Lycra Sports Fabric can be stamped from single sheets of material. In addition, this figure also illustrates the thermal pack apertures 9. In a preferred embodiment, the thermal pack apertures 9 were formed in the inside Poron layer and the inside Lycra Sports Fabric layer such that thermal packs can be inserted into the thermal safety helmet 1 to either heat or cool the affected areas of the patient's head asked the patient's needs dictate. Also illustrated in this figure are the chinstrap aperture 5, the ear apertures 6, and the ventilation apertures 2. Those skilled in the art will recognize that the thermal safety helmet 1 can be structured such that the thermal packs can be inserted from the exterior of the thermal safety on 1. However, in the preferred embodiment the thermal packs are inserted on the inside in order to maintain the desired temperature for as long as possible.

In the event that the thermal packs are inserted into pockets 3 on the external side of the thermal safety helmet 1, each external pocket 3 may use an access flap that seals the external pocket once the thermal pack is installed. While the access flap can use any suitable means to secure the thermal pack, the preferred embodiment envisions hook and loop material as the sealing means.

The thermal packs can be fabricated from any suitable material. They can be commercially available “blue ice” packs, they can be chemical packs, etc. Further, the thermal packs can provide heat or cold thermal effects, as needed. In the preferred embodiment, the thermal pack is a non-toxic gel pack.

The following embodiments are directed to helmets 10 fabricated from EVA. Those skilled in the art will recognize that these helmets 10 can be fabricated with a unitary shell 11, or fabricated with the shell 11 and an external cover 12 (shown in FIG. 11). The external cover 12 can be fabricated using any suitable material such as fabric, etc.

FIG. 7 is a front view of a preferred embodiment of an EVA safety helmet 10 with an optional chinstrap 3 secured to the shell 11 of the helmet 10. This embodiment uses an alternative strap retention loop 14 instead of the strap attachment aperture 5 used in the previous embodiments. Those skilled in the art will recognize that either method of retaining the chinstrap 3 can be used. An advantage of this configuration is the reduced number of components over the prior art. Using a single piece molded shell 11 simplifies the design reduces manufacturing cost. The EVA shell 11 can vary in thickness, but should have sufficient thickness to provide protection to the wearer. While dimensions can vary, a thickness from 0.5 to 1.5 inches is adequate for most activity.

FIG. 8 is a top view of a preferred embodiment of the EVA safety helmet 10 showing ventilation apertures 2 on the upper surface of the shell 11.

FIG. 9 is a left side view of a preferred embodiment of the EVA safety helmet 10 showing an ear aperture 6, and a strap retention loop 14 on the surface of the shell 11.

FIG. 10 is a rear view of a preferred embodiment of the EVA safety helmet 11 showing a chinstrap 3 attached to it, and ventilation apertures 2 on the rear surface of the helmet 10. The chinstrap 3 has hook and loop segments 8 that secure the chinstrap 5 to the helmet 10 when it is inserted through strap retention loop 14.

FIG. 11 is a cross-sectional view of a preferred embodiment of the EVA shell showing an internal EVA layer 13 with optional external covers 12 on either side. External covers can be any suitable material such as fabric. Likewise, external covers 12 can be removable to allow a convenient method of cleaning.

In addition to the foregoing, the helmet provides for optional features. For example FIG. 12 is a side view of a preferred embodiment of the EVA helmet 10 showing an optional ornamental image 15 on the side of the helmet. For illustrative purposes, image 15 is shown as a tiger, but those skilled in the art will recognize that there is no limit to the types of images that may be used. For example, school logos, political images, sports logos, company logos, religious images, etc. may be used as embellishments to the helmet 10.

In addition to ornamental images, this embodiment can also take advantage of the optional chin pad sleeve 7 discussed above in regard to FIG. 4. While optional chin pad sleeve 7 can be fabricated from any suitable material, the preferred embodiment uses SBR foam that is secured to the chin strap 3 via hook and loop material after chin strap 3 has been tightened. SBR foam (styrene-butadiene rubber) is commercially available from a wide variety of sources.

While the embodiments of FIGS. 7-11 can be solely directed to the USE of EVA for improved performance, those skilled I the art will recognize that the integral cooling system taught in FIGS. 1-6 can be combined with the EVA structure in FIGS. 7-11 to provide an improved helmet that provides both temperature control and improved impact protection for anyone concerned about head injuries.

While specific embodiments have been discussed to illustrate the invention, it will be understood by those skilled in the art that variations in the embodiments can be made without departing from the spirit of the invention. For example, the thickness of the materials used to fabricate the helmet can vary, the number and location of the ventilation apertures can vary, the method of securing the helmet to the patient's head can vary, etc. Therefore, the invention shall be limited solely to the scope of the claims. 

I claim:
 1. A impact resistant safety helmet, comprising: a helmet shell fabricated substantially from EVA; and the shell extending over a wearer's head such that the wearer is protected from impact injuries.
 2. A helmet, as in claim 1, further comprising: a releasable chinstrap secured to the EVA safety helmet at its proximal end; and the distal end of the releasable chinstrap having connection means to secure the distal end of the releasable chinstrap to the EVA safety helmet.
 3. A helmet, as in claim 2, wherein: the connection means is full and loop material.
 4. A helmet, as in claim 3, further comprising: a chinstrap aperture in the helmet sized such that a releasable chinstrap fits through the chin strap aperture.
 5. A helmet, as in claim 1, wherein: the EVA helmet shell is enclosed in an outer cover.
 6. A helmet, as in claim 5, wherein: the outer cover is removable.
 7. A helmet, as in claim 5, wherein: the shell has pockets for retaining thermal packs. 